Toyota Forklift 7FBCU15, 7FBCU18, 7FBCU20, 7FBCU25, 7FBCU30, 7FBCU32, 7FBCU35, 7FBCU45, 7FBCU55, 7FBCHU25 Service Manual

Introducing the Toyota Electric Forklift Truck Type 7FBCU Workshop Service Manual.

This manual is an illustrated guide designed specifically for Toyota (BT) Forklift Trucks. With high quality images, circuit diagrams, and instructions, it provides all the necessary information to operate, maintain, and repair your truck.

All manuals are printable and feature searchable text and navigation bookmarks for easy access.

Models covered:

• 7FBCHU25
• 7FBCU15
• 7FBCU18
• 7FBCU20
• 7FBCU25
• 7FBCU30
• 7FBCU32
• 7FBCU35
• 7FBCU45
• 7FBCU55

Format: 918 Pages

Language: English

Contents:

• GENERAL
• EXTERIOR VIEWS
• VEHICLE MODEL
• FRAME NUMBER
• HOW TO USE THIS MANUAL
• EXPLANATION METHOD
• TERMINOLOGY
• ABBREVIATIONS
• OPERATIONAL TIPS
• JACK-UP POINT
• HOISTING THE VEHICLE
• CAUTION FOR TOWING
• ATTENTIVE POINTS ON SAS
• CIRCUIT TESTER
• STANDARD BOLT & NUT
• TIGHTENING TORQUE
• BOLT STRENGTH TYPE IDENTIFICATION METHOD
• TIGHTENING TORQUE TABLE
• PRECOAT BOLTS
• HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
• WIRE ROPE SUSPENSION ANGLE LIST
• SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
• COMPONENTS WEIGHT
• RECOMMENDED LUBRICANT QUANTITY & TYPES
• LUBRICATION CHART
• PERIODIC MAINTENANCE
• PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
• BATTERY
• BATTERY COMPARTMENT AND REQUIRED WEIGHT
• SERVICE STANDARD
• DISPLAY
• TROUBLESHOOTING
• BATTERY ASSY
• REMOVAL-INSTALLATION
• INSPECTION
• CONTROLLER
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• CONTROLLER
• TRAVELINGIMATERIAL HANDLING CONTROLLER ASSY
• REMOVAL-INSTALLATION (15 - 32 MODEL)
• TRAVELING CONTROLLER ASSY REMOVAL-INSTALLATION (35 - 55 MODEL)
• MATERIAL HANDLING CONTROLL ASSY REMOVAL-INSTALLATION (35 - 55 MODEL)
• TRAVELING AND MATERIAL HANDLING CONTROLLER
• INSPECTION
• CONTACTOR PANEL ASSY REMOVAL.INSTALLATlON (1 5 - 32 MODEL)
• CONTACTOR PANEL ASSY REMOVAL-INSTALLATION (35 - 55 MODEL)
• CONTACTOR PANEL
• INSPECTION
• PS CONTROLLER ASSY REMOVAL-INSTALLATION (15 - 32 MODEL)
• PS CONTROLLER INSPECTION (15 - 32 MODEL)
• SAS CONTROLLER ASSY REMOVAL-INSTALLATION
• BOARD INSPECTION
• DISASSEMBLY
• REASSEMBLY
• DISPLAY INSPECTION
• DIRECTION SWITCH
• REMOVAL-INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY
• ACCELERATOR POTENTIOMETER ADJUSTMENT
• BRAKE SWITCH ADJUSTMENT
• FOOT BRAKE
• PARKING BRAKE
• MATERIAL HANDLING LEVER SWITCH ADJUSTMENT
• EZ PEDAL (OPT)
• COMPONENTS
• INSPECTION
• MULTI-DISPLAY FUNCTIONS
• MULTIPLE DISPLAY
• GENERAL
• GENERAL FUNCTIONS
• DISPLAY INDICATION LIST
• SPECIFICATIONS
• ABBREVIATIONS DISPLAYED ON THE SCREEN
• NORMAL FUNCTION SCREEN
• USA SPECIFICATION MODEL
• EXPORT MODEL
• MASK FUNCTIONS
• GENERAL
• MANAGER'S FUNCTION
• SERVICE FUNCTION
• ANALYZER
• TUNING
• OPTION SET
• MATCHING
• WHEEL DIA
• DIAGNOSIS
• DIAGNOSIS CODE LIST
• TROUBLESHOOTING
• BEFORE TROUBLESHOOTlNG
• CONNECTOR HANDLING
• WIRE HARNESS AND CONNECTOR
• INSPECTION PROCEDURE
• TROUBLESHOOTING METHOD
• EXPLANATION OF BOXES
• SST SETTING METHODS (15 - 32 MODEL)
• CPU BOARD CONNECTOR
• DGIUD BOARD CONNECTOR
• ST BOARD CONNECTOR
• EHPS BOARD CONNECTOR
• TRAVELINGIMATERIAL HANDLING CONTROLLER (CHOPPER-LESS) CONNECTOR-COMPONENT
• TRAVELINGIMATERIAL HANDLING CONTROLLER (CHOPPER) CONNECTOR*COMPONENT
• SAS CONTROLLER CONNECTOR*COMPONENT
• EHPS CONTROLLER CONNECTOR*COMPONENT
• EHPS CONTROLLER CONNECTOR*COMPONENT
• CONTACTOR PANEL CONNECTOR*COMPONENT
• TROUBLESHOOTING (15-32 MODEL)
• COMPOSITION LIST
• TRAVELlNGlMATERlAL HANDLING SYSTEMS
• WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
• WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED
• STEERING SYSTEM
• WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
• WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED
• MULTI-DISPLAY - MCS COMMUNICATION SYSTEM
• WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
• WHEN NO DIAGNOSIS ERROR CODE IS DISPLAYED
• SAS SYSTEM WHEN A DIAGNOSIS ERROR CODE IS DISPLAYED
• WHEN NO ERROR CODE IS DISPLAYED
• MOTOR
• DRIVE MOTOR
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL-INSTALLATION (15 - 32 MODEL)
• REMOVAL-INSTALLATION (35 - 55 MODEL)
• DISASSEMBLY-INSPECTI0N-REASSEMBLY (15 - 32 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
• PUMP MOTOR
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL-INSTALLATION (15 - 32 MODEL)
• REMOVAL-INSTALLATION (35 - 55 MODEL. NO.l)
• REMOVAL-INSTALLATION (35 - 55 MODEL. NO.2)
• DISASSEMBLY-INSPECTION REASSEMBLY
• POWER STEERING MOTOR (15- 32 MODEL)
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL, INSTALLATION, DISASSEMBLY, INSPECTION, REASSEMBLY
• MOTOR BRUSH WEAR AND OVERHEAT WARNING
• INSPECTION
• DRIVE UNIT
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• DRIVE UNIT ASSY (15 - 32 MODEL)
• REMOVAL-INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY (15-18 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (15-18 MODEL (DEAD-MAN BRAKE) 20 - 32 MODEL)
• DRIVE UNIT ASSY (35 - 55 MODEL)
• REMOVAL.INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY
• DIFFERENTIAL CASE ASSY
• DISASSEMBLY-INSPECTION-REASSEMBLY (15 - 32 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
• FRONT AXLE
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• FRONT AXLE SHAFT-AXLE HUB (15 - 32 MODEL)
• REMOVAL.INSTALLATION
• FRONT AXLE SHAFTaAXLE HUB (35 - 55 MODEL)
• REMOVAL-INSTALLATION
• FRONT AXLE BRACKETmAXLE HOUSING (15 - 32 MODEL)
• REMOVAL-INSTALLATION
• DIFFERENTIAL HOUSING (35 - 55 MODEL)
• REMOVAL-INSTALLATION
• REAR AXLE
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REAR AXLE ASSY (15 - 32 MODEL)
• REMOVAL-INSTALLATION
• REAR AXLE ASSY (35- 55 MODEL)
• REMOVAL.INSTALLATION
• STEERING KNUCKLE (15 - 32 MODEL)
• REMOVAL-INSTALLATION
• STEERING KNUCKLE (35 - 55 MODEL)
• REMOVAL-INSTALLATION
• REAR AXLE CYLINDER
• REMOVAL.INSTALLATION (15 - 32 MODEL)
• REMOVAL-INSTALLATION (35 - 55 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY
• STEERING
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• STEERING WHEEL-MAST JACKET
• REMOVAL-INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY
• HYDROSTATIC STEERING VALVE ASSY
• TROUBLESHOOTING
• REMOVAL.INSTALLATION
• DISASSEMBLY.INSPECTl0N.REASSEMBLY
• RELIEF PRESSURE
• INSPECTlON.ADJUSTMENT
• POWER STEERING PUMP ASSY (15 - 32 MODEL)
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL-INSTALLATION
• BRAKE
• GENERAL
• SPEClFlCATlONS
• COMPONENTS
• FRONT BRAKE
• DISASSEMBLY-INSPECTION
• REASSEMBLY (15 - 32 MODEL)
• DISASSEMBLY.INSPECTION
• REASSEMBLY (35-45 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (55 MODEL)
• DEAD-MAN BRAKE (OPT)
• DISASSEMBLY.INSPECTION
• REASSEMBLY
• BRAKE AIR BLEEDING (15 - 32 MODEL)
• BRAKE AIR BLEEDING (35 - 55 MODEL)
• BRAKING FORCE INSPECTION ADJUSTMENT
• DEAD-MAN BRAKE ADJUSTMENT
• BRAKE MASTER CYLINDER (15 - 32 MODEL)
• REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
• BRAKE BOOSTER
• TROUBLESHOOTING
• REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
• DEAD-MAN BRAKE CYLINDER
• REMOVAL.INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
• DEAD-MAN BRAKE SOLENOID
• REMOVAL-INSTALLATION- DISASSEMBLY-INSPECTION-REASSEMBLY
• DEAD-MAN BRAKE RELIEF VALVE (15 - 32 MODEL)
• REMOVAL-INSTALLATION-DISASSEMBLY-INSPECTION-REASSEMBLY
• PARKING BRAKE INSPECTION
• ADJUSTMENT
• DEAD-MAN BRAKE WIRE
• INSPECTION-ADJUSTMENT (15 - 32 MODEL)
• DEAD-MAN BRAKE WlRE
• INSPECTION-ADJUSTMENT (35 - 55 MODEL)
• BRAKE PEDAL INSPECTION ADJUSTMENT (15 - 32 MODEL)
• BRAKE PEDAL INSPECTION ADJUSTMENT (35 - 55 MODEL)
• BODY
• COMPONENTS
• BATTERY HOOD ASSY
• REMOVAL-INSTALLATION
• COUNTERWEIGHT
• REMOVAL-INSTALLATION
• DRIVER'S SEAT
• REMOVAL-INSTALLATION
• FUSE (1 5 - 32 MODEL)
• FUSE MOUNTING POSITION
• NAMES (APPLICABLE PORTIONS) AND CAPACITIES
• FUSE (35 - 55 MODEL)
• FUSE MOUNTING POSITION
• NAMES (APPLICABLE PORTIONS) AND CAPACITIES
• MATERIAL HANDLING SYSTEM
• HYDRAULIC SYSTEM DIAGRAM
• COMPONENTS
• RETURN FILTER-SUCTION FILTER
• REMOVAL-INSTALLATION (1 5 - 32 MODEL)
• REMOVAL-INSTALLATION (35 - 55 MODEL)
• NATURAL DROP TEST
• NATURAL FORWARD TILT TEST
• OIL LEAK TEST
• LIFT CYLINDER
• TILT CYLINDER
• MAST
• V MAST ASSY
• COMPONENTS
• REMOVAL-INSTALLATION
• REMOVAL-INSTALLATION (WILIFT BRACKET)
• MAST DISASSEMBLY-INSPECTION-REASSEMBLY
• LIFT BRACKET
• DISASSEMBLY-INSPECTION-REASSEMBLY
• MAST ADJUSTMENT (V MAST. 15 - 32 MODEL)
• MAST ADJUSTMENT (V MAST. 35 - 55 MODEL)
• MAST ROLLER REMOVAL INSTALLATION
• CHAIN (15 - 32 MODEL)
• INSPECTION
• REASSEMBLY (V-FV-FSV)
• REASSEMBLY (QFV)
• ADJUSTMENT
• CHAIN (35 - 55 MODEL)
• INSPECTION
• REASSEMBLY (V-FV-FSV)
• ADJUSTMENT
• FORK
• REMOVAL
• INSTALLATION
• INSPECTION
• FV*FSV MAST ASSY
• COMPONENTS
• MAST ADJUSTMENT (FVmFSV. 15 - 32 MODEL)
• MAST ADJUSTMENT (FV-FSV MAST. 35 - 55 MODEL)
• QFV MAST ASSY
• COMPONENTS
• MAST ADJUSTMENT (QFV)
• LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)
• CYLINDER
• LIFT CYLINDER (V)*REAR LIFT CYLINDER (FV*FSV*QFV)
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL-INSTALLATION (15 - 32 MODEL)
• REMOVAL-INSTALLATION (35 - 55 MODEL)
• DISASSEMBLY-INSPECTION -REASSEMBLY (15 - 32 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
• FLOW REGULATOR VALVE
• REMOVAL-INSTALLATION (35 55 MODEL)
• SAFETY DOWN VALVE
• REMOVAL-INSTALLATION (35 - 55 MODEL)
• FRONT LlFT CYLINDER (FV*FSV-QFV)
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL-INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY (15 - 32 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
• TILT CYLINDER
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• REMOVAL-INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY
• MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT (PREVENTION OF UNEVEN TILTING)
• OIL PUMP
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• OIL PUMP ASSY
• REMOVAL-INSTALLATION (15 - 32 MODEL)
• REMOVAL-INSTALLATION (35 - 55 MODEL NO.l PUMP)
• REMOVAL-INSTALLATION (35 - 55 MODEL N0.2 PUMP)
• DISASSEMBLY-INSPECTION-REASSEMBLY (15-32 MODEL. 35-55 MODEL N0.2 PUMP)
• DISASSEMBLY-INSPECTI0N.REASSEMBLY (35-55 MODEL NO.l PUMP)
• TEST METHOD
• OIL CONTROL VALVE
• GENERAL
• SPECIFICATIONS
• COMPONENTS
• OIL CONTROL VALVE ASSY
• REMOVAL-INSTALLATION
• DISASSEMBLY-INSPECTION-REASSEMBLY (15 - 32 MODEL)
• DISASSEMBLY-INSPECTION-REASSEMBLY (35 - 55 MODEL)
• LlFT & TILT LOCK VALVE ASSY (35 - 55 MODEL)
• REMOVAL-INSTALLATION
• DISASSEMBLY.INSPECTI0N.REASSEMBLY
• RELIEF PRESSURE ADJUSTMENT
• LlFT LOCK UNLOCKING BOLT (15 - 32 MODEL)
• CONTROL VALVE LEVER ASSY
• REMOVAL-INSTALLATION
• SAS FUNCTIONS
• GENERAL
• COMPONENTS
• BEFORE STARTING REPAIR WORK
• YAW RATE SENSOR
• REMOVAL.INSTALLATION
• SWING LOCK CYLINDER
• REMOVAL-INSTALLATION
• TILT ANGLE SENSOR
• REMOVAL.INSTALLATION
• LOAD SENSOR
• REMOVAL.INSTALLATION
• SPEED SENSOR
• REMOVAL-INSTALLATION
• MAST LIFTING HEIGHT SWITCH
• REMOVAL-INSTALLATION
• MATCHING
• STANDARD STATE OF VEHICLE
• CAUTIONS ON MODIFYING VEHICLES
• RENEWAL OF SAS CAUTION LABEL
• APPENDIX
• SST LIST
• SERVICE STANDARDS
• CONNECTOR DRAWING (15 - 32 MODEL)
• CONNECTOR DRAWING (35 - 55 MODEL)
• CONNECTING DIAGRAM (15 - 32 MODEL)
• CONNECTING DIAGRAM (35 - 55 MODEL)
• WIRING DIAGRAM (15 - 32 MODEL)
• WIRING DIAGRAM (35 - 55 MODEL)